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Technical Data & Terms Aluminum PREMIUM FLUX-COATED ALUMINUM JOINING AND BUILD-UP ALLOY FOR ARC OR TORCH General Characteristics Universal aluminum electrode for arc welding aluminum and aluminum alloys. Welds are strong, dense on both production and maintenance applications. Arc is exceptionally stable, operates at low amperes with a minimum of spatter and fuming. Weld deposits have good color match and corrosion resistance. Ideal for welding heat treated aluminum parts. Can also be used as a flux coated aluminum joining and build-up rod for use with oxyacetylene. Applications Repairing of automotive, truck and bus parts. Also for tanks, pipes, ladders, shelves and many other aluminum structures. Repair of machining errors and build-up of missing sections of castings, extrusions, plates, etc. Technical Data Typical Tensile Strength: up to 34,000 psi (24 kg/mm2) Elongation %: 15-25 Typical Hardness (HB): 40-55 Color Match: good (will darken if anodized) Current: DC reverse polarity only (electrode +) Amperage: 80-130 1/8" 3.25mm Procedure Clean weld area thoroughly prior to welding with a stainless steel wire brush. Parts 1/8" or heavier should be beveled 70-90. No preheat is necessary on thin gauges but faster, flatter, smoother welds are produced on heavier sections if they are preheated to approximately 400F (205C) Hold electrode vertical to workpiece, maintain a short arc and fast travel speed. Use either stringer beads or weaving technique. Remove slag between passes. Restart arc on existing weld deposits. Allow part to cool

slowly. Chip off all slag before quenching. Always remove all slag residue.

Brazing MULTI-DEOXIDIZED LOW FUMING BRONZE BARE AND FLUX COATED General Characteristics Brazing alloy is available both bare and flux-coated. The bare rods are for use with US Forge Brazing Flux. The flux-coated rods eliminate the need for additional fluxes, therefore they usually prove to be more economical. Both the bare and flux-coated rods are made to meet todays industry standards. Applications Maintenance repair of most ferrous and non-ferrous metals. Ideal for joining parts of metal furniture, bicycles, automobiles and many more items where heat distortion does not allow for arc welding. Technical Data Nominal Analysis: Cu-58%, Sn-1.0%, Mn-0.40%, Fe0.75%, Si-0.10%, Zn-remainder Working Temperature: 1600F (870C) Typical Hardness (HB): 80-110 Specifications: AWS A5.7 Class R CuZn-C ASTM B259 Class R CuZn-C QQ-R-571a (FS-R CuZn-3) Diameter: 3/32" 1/8" 2.5mm 3.25mm Procedure Use slightly oxidizing flame concentrated on the base metal. When using bare rods, heat end of rod, dip into US Forge flux and transfer to the working area. Put the torch flame where the alloy is wanted; the molten alloy will follow the heat. Do not overheat; the base metal must not be melted except when fusion welding bronze parts. Allow to cool slowly. Remove flux residue with chipping hammer and wire brush.

Cast Iron MAXIMUM STRENGTH ALLOY FOR DIRTY CAST IRON General Characteristics Unique flux coating on alloyed core wire produces dense, strong, crack-resistant welds on virtually all types of cast iron. Especially good for contaminated, old, oil-soaked, dirty base metal. Also recommended for joining cast iron to steel. Use on gray, ductile, Meehanite and nodular cast iron. Deposits are machinable. Applications Use on machine bases, transmission or gear housings, sprockets, repair of or build-up on gears and any repair of cast iron to steel. Technical Data Typical Tensile Strength: up to 60,000 (42 kg/mm2) Typical Hardness (HB): Brinell 210 Current: AC or DC reverse polarity (electrode +) Amperage: 70-110 Diameter : 1/8" 3.25mm Procedure On heavy sections, remove worn, cracked metal, and bevel joint using the US Forge Cutting rod or a grinding wheel. When repairing cracks, drill stop hole at either end to prevent crack travel while welding. Use short stringer beads. Use a short to medium arc length and the lowest amperage possible to minimize base metal overheating. When breaking arc, always back step into weld crater. Weld joints should be allowed to slow cool for maximum strength and machinability.

Cutting HIGH SPEED GOUGING AND CHAMFERING ELECTRODE General Characteristics A highly efficient electrode that performs with all types of welding machines with sufficient capacity*. The forceful

arc-blow is produced by the special coating which eliminates the need for compressed air or oxygen. The size and depth of the groove can be easily controlled. Dross practically falls off; cut is smooth, uniform and can be done in all positions. *Contact Technical Service at 800-343-3758 for assistance. Applications Gouging and chamfering of ferrous and non-ferrous metals. Removing unwanted or defective weld metal, preparing parts prior to welding, removing risers and reducing large areas of metal prior to machining. Technical Data Current: AC or DC straight polarity (electrode -) Amperage: 100-250 Diameter: 3/32" 2.5mm Procedure For clean high speed cuts use DC straight polarity (electrode - ) Hold electrode at a low angle to the workpiece (10 to 15). Point the electrode in the direction of the desired groove, strike the arc and push the electrode as fast as the metal is removed. Maintain contact with the electrode to the work-piece when gouging. The maximum depth of the groove in a single pass should not be greater than the diameter of the core wire. For deep grooves, use multiple passes.

Nickel 55 NICKEL-IRON ELECTRODE FOR WELDING CAST IRON AWS-ENiFE-CI General Characteristics A nickel-iron type electrode for welding cast iron in all positions. This electrode produces welds with higher strengths than the straight nickel electrodes. Deposits are machinable, but harder and more resistant to abrasion than high-nickel welds. Applications Welding cast irons and nodular iron and joining these irons to steel and other ferrous and non- ferrous materials. Also

for heavy sections of high-strength and engineering-grade cast iron. Commonly used to weld high-phosphorus irons and steels, ductile iron and high-nickel alloy cast iron. Technical Data Current: AC or DC reverse polarity (electrode +) Amperage: 40-95 70-120 Diameter: 3/32" 1/8" 2.5mm 3.25mm Specifications: AWS A5.15 Class ENiFe-CI Procedure When preheat is required, preheat cast iron parts to 600F (315C). Steels and other materials usually do not require preheat unless they are complicated and contain excessive stresses. Use stringer beads or narrow weave beads. Remove slag between passes when making multiple layers. Maintain preheat temperature during entire welding operation; when completed allow part to cool very slowly.

Nickel 99 NICKEL ELECTRODE FOR WELDING CAST IRON AWS - ENi-CI General Characteristics A high nickel content electrode with an extruded coating for welding cast iron. Welds are easily produced in all positions and the deposits are readily machined. Applications Used to join ordinary gray irons to themselves or to other ferrous and non-ferrous materials. Also for repair of castings when machining is to be done after welding. Welds can be satisfactorily produced on light and mediumsize castings. Technical Data Current: AC or DC reverse polarity (electrode +) Amperage: 40-75 65-115 Diameter: 3/32 1/8 2.5mm 3.25mm SPECIFICATIONS: AWS A5.15 Class ENi-CI

Procedure In most cases preheating or post-heating will not be necessary, but in cold weather or when special machining qualities are desired the part should be preheated to 400F (204C) Stringer beads and intermittent welds should be employed to reduce stresses and cracks; peening while still hot also helps reduce these problems. Allow part to cool slowly.

Problem Solver THE STRONGEST, PROBLEM SOLVING, UNIVERSAL ELECTRODE FOR ALL STEELS General Characteristics A low heat input electrode designed to produce the highest tensile welds. It can be used in all positions to produce smooth, porosity free welds without undercut or spatter. Applications Welding low, medium, and high alloy steels requiring the highest strength and quality. Ideal for repair of springs, carbon steels, stainless steels, and as an underlayment or buffer prior to applying hardfacing alloys. Commonly used for joining stainless steels of unknown analysis and these steels to carbon steels. Ideal for broken stud removal. Technical Data Typical Tensile Strength: as welded up to 120,000 psi (84 kg/mm2) work hardens up to 180,000 psi (126 kg/mm2) Typical Yield Strength: up to 90,000 psi (63 kg/mm2) Elongation %: approx. 28 Typical Hardness (HB): approx. 300 Current: AC or DC reverse polarity (electrode+) Amperage: 65-120 Diameter: 1/8" 3.25mm Procedure Prepare joint area by removing foreign material. Bevel heavy sections to form a 90 vee. Preheat high carbon steels to 400F (204C). Use jigs, fixtures and tack welds to maintain alignment. Hold a short arc. Stringer beads are preferred to prevent overheating. Allow to cool before

removing slag. Deposits will take a high polish when subjected to wear. All welds on stainless steel should be cleaned with a stainless steel wire brush.

RustBuster PREMIUM, HIGH STRENGTH, ALL POSITION ELECTRODE FOR QUALITY WELDS ON VERY DIRTY, RUSTY AND PAINTED STEELS General Characteristics The special premium coating on Rustbuster allows it to weld over extremely dirty, greasy, oil soaked and/or rusty steels. It can also weld over its own slag without causing inclusions or slag interference. The low amperage capability makes it excellent for poor fit-up applications and use on low, open circuit voltage buzz boxes. It is not necessary to chip slag between passes. Applications Ideal for maintenance applications where poor fit-up is encountered. Welds are also easily made on equipment or machines that are covered with grease and sand that cant be cleaned before welding. Designed for machine and automotive repair as well as general construction and fabrication. Technical Data Typical Tensile Strength: up to 85,000 psi (58 kg/mm2) Typical Yield Strength: up to 69,000 psi (48 kg/mm2) Elongation %: . approx. 25 Current: AC or DC (either polarity) Amperage: 20-100 30-140 3/32" 1/8" 2.5mm 3.25mm Deposition Rate:(lbs. per hour) 1.2-2.0 1.9-2.6 Procedure If possible, clean the weld areas as much as is practical. Set the amperage to the specific requirements. If an edge build-up is required or it is thin steel, use the lower end of the amperage range. If heavy penetration is required or the weld area is extremely dirty use the higher end of the amperage range. A close to medium arc gap should be maintained. Slag chipping is recommended, but not

necessary on multi-pass applications.

Steel PREMIUM QUALITY, EASIEST-TO-USE, ALL POSITION ELECTRODE FOR MILD STEEL General Characteristics This electrode has been designed to operate on almost any AC or DC welding machine even when the open circuit voltage is very low. The special coating protects the weld deposit from adverse conditions normally encountered in maintenance repair welding. Low amperage requirement controls distortion when welding thin sheet metal. Virtually no spatter. Easiest to use electrode for out-of-position welding. Ideal for field work. Applications Ideal for fabrication of thin and medium gauge mild steels. Plate and angle iron can be easily welded in all positions. Also used for filling holes or build up of worn or over machined low carbon steel surfaces. Technical Data Typical Tensile Strength: up to 80,000 psi (56 kg/mm2) Typical Yield Strength: up to 68,000 psi (47 kg/mm2) Elongation%: approx. 24 Current: AC or DC either polarity Amperage: 35-80 65-125 3/32" 1/8" 2.5mm 3.25mm Procedure Clean weld area of all contaminants (rust, etc.) prior to welding. DC reverse polarity (electrode +) produces deep penetration; DC straight polarity (electrode - ) will have limited penetration and a flatter bead. AC prevents arc blow. A medium arc length should be maintained with either stringer or weave beads. Slag is easily removed with a light chipping hammer.

WearFacing SUPERIOR HIGH ALLOY ELECTRODE FOR MEDIUM IMPACT AND SEVERE ABRASION General Characteristics High deposition rate electrode that produces smooth beads and in most cases the slag comes off all by itself. The arc is easily controlled and prevents excessive dilution with the base metal. The high chromium content of these electrodes makes the weld deposits maintain their resistance even at elevated temperatures. Applications Parts subjected to severe abrasion but with light impact such as equipment for processing soil, rock, coal, cement, ceramic matter, grinding plates, dredger teeth, conveyor and press screws, coal augers, agitators, earth augers and scrapers, snowmobile wear bars and snowplow edges. Technical Data Typical Hardness as welded: Rc 56-60 Current: AC or DC reverse polarity (electrode +) Amperage: 80-125 Diameter: 1/8" 3.25mm Procedures Remove foreign material and unsound metal from surface to be welded. For best results and long service life an elastic cushion layer should be applied to the part before surfacing with this electrode. Use Problem Solver for a cushion layer on carbon steels and manganese steels, on cast iron use Nickel 99. When making the final surface with US Forge Wearfacing keep electrode vertical to the workpiece and maintain a short arc. Deposits must be kept thin, never more than two layers thick. To prevent excessive local heat build-up in the part, alternate welding area. Allow part to cool slowly.

308L Stainless Steel GENERAL PURPOSE, LOW CARBON STAINLESS STEEL ELECTRODE

General Characteristics High quality general purpose stainless steel electrode with a low carbon content that has excellent welding characteristics. The arc is very smooth and easy to control in all positions. It has outstanding arc-starting and restarting features with easy slag removal. Applications Welding on 302, 304, 308 and 347 stainless steels. Designed for use on all normal and low carbon stainless steels except the molybdenum-bearing austenitic alloys. Ideal for welding materials that are subject to carbide precipitation. Normally used to repair household appliances, tanks, pipes and fittings. Technical Data Typical Tensile Strength: up to 100,000 psi (70 kg/mm2) Typical Yield Strength: up to 62,000 psi (44 kg/mm2) Elongation %: approx. 40 Corrosion Resistance: good Current: AC or DC reverse polarity (electrode +) Amperage: 25-35 35-50 40-90 75-120 1/16" 5/64" 3/32" 1/8" 1.6mm 2.0mm 2.5mm 3.25mm Procedure Thoroughly clean weld area of all foreign material with a stainless steel wire brush. A 60 bevel should be used when butt welding parts 3/16" (5.0mm) and heavier. Do not preheat. Tack parts to maintain alignment. Hold a medium short arc with electrode tilted at 15 in the direction of travel. Prevent excessive heat build-up during welding operations. Remove slag between passes. Allow to cool slowly.

E6011 ALL-POSITION, DEEP PENETRATING FAST FREEZE ELECTRODE. WELDS ON RUSTY OR PAINTED SURFACES. General Characteristics E6011 quality electrode with a forceful arc to penetrate

scale, rust, paint and other contaminants. It has excellent operating characteristics in all positions. Use with AC or DC either polarity. Applications Use on galvanized steels and steels that may have scale, rust or paint on the surfaces to be welded. Technical Data Typical Tensile Strength: up to 72,000 psi (50kg/mm2) Typical Yield Strength: 67,000 psi (48kg/mm2) Elongation (in 2 inches): 24% Current: AC or DC either polarity Amperage: 40-85 70-135 110-175 3/32" 1/8" 5/32" 2.5mm 3.25mm 4.0mm SPECIFICATIONS: AWS A5.1, ASME SFA 5.1 Class E6011 Procedures Weld area should be as clean as possible. Set amperage to the low side of the range for thin material, to the high side for heavier sections and surfaces containing scale, rust, paint or grease. Hold medium arc length for flat position. Use a slight weaving technique for vertical up. Vertical down requires higher amperage and fast travel speed. Wire brush between passes.

E6013 GENERAL PURPOSE ELECTRODE FOR MILD STEEL. EXCELLENT FOR LIGHT GAUGE WORK ALL POSITION General Characteristics For all types of mild steel fabrication. Ideal for light gauge work. Best electrode available for vertical and overhead welding. Applications Use for general production and repair work. Generally used for thin sections and sheet metal. For farm, industrial and construction where light fabrication and repair work is performed on a regular basis.

Technical Data Typical Tensile Strength: up to 80,000 psi (56 kg/mm2) Typical Yield Strength: 68,000 psi (48 kg/mm2) Elongation: 24% Current: AC or DC either polarity Amperage: 30-80 80-120 120-190 Diameter: 3/32" 1/8" 5/32" 2.5mm 3.25mm 4.0mm Procedure Joints should be as clean as possible and close fitting. Use DC straight polarity for shallow penetration. DC reverse polarity will give deeper penetration. Excellent for use with low open circuit voltage AC welders. Tip the electrode slightly in the direction of travel. Maintain a close arc gap and use either stringer beads or slight weave. Slag is virtually self releasing.

E7014 HIGH DEPOSITION MILD STEEL ELECTRODE. ALL POSITION General Characteristics Added iron powder in the coating gives this electrode increased deposition. Shallow penetration, quick solidification, excellent restrike characteristics, easy slag removal and excellent bead appearance makes this electrode excellent for all position work. Applications Production and repair of mild steel. Use on farm, industrial, and construction equipment. Excellent restrike characteristic and drag technique makes this electrode a favorite of all welders. Technical Data Typical Tensile Strength: up to 81,000 psi (56 kg/mm2) Typical Yield Strength: 73,000 psi (51 kg/mm2) Elongation: 26% Current: AC or DC either polarity Amperage: 80-125 110-150 140-190 3/32" 1/8" 5/32" 2.5mm 3.25mm 4.0mm

Procedures While special preparation of the base metal is not necessary in many cases, best results are obtained by first cleaning the weld area of grease, oxides or rust. Maintain a short arc. Use stringer beads or weave beads. When making stringer beads, a drag type technique may be used.

E7018 QUALITY, LOW HYDROGEN ELECTRODE WITH MOISTURE GUARD COATING. FOR X-RAY QUALITY WELDS ON CONSTRUCTION STEELS. General Characteristics E7018 quality, iron powder low hydrogen electrode designed for joining construction grade and problem steels. Product features a moisture guard coating to minimize hydrogen embrittlement and under-bead cracking. Weldability is excellent on both AC and DC reverse polarity. The first choice for x-ray quality welds featuring high impact resistance. Applications Used primarily on carbon and medium tensile steels, especially under conditions of restraint. Excellent for high sulphur and tramp steels, boiler plate and cast steel. Technical Data Typical Tensile Strength: up to 76,000 psi (54kg/mm2) Typical Yield Strength: 69,000 psi (49kg/mm2) Elongation (in 2 inches): 30% Current: AC or DC (reverse polarity) Amperage: 60-100 110-150 140-200 3/32" 1/8" 5/32" 2.5mm 3.25mm 4.0mm SPECIFICATIONS: AWS A5.1, ASME SFA 5.1 Class E7018 Procedure Area to be welded should be clean and free of surface contamination such as rust, scale, grease, etc. On DC, use reverse polarity (electrode +) Preheat of 400 to 450 should be employed with heavy sections and hardenable grades of base metal. For highest x-ray quality, maintain a

short arc gap. On vertical welds, start at bottom and weave slightly while pausing at the edges. For root passes, set a minimum gap (3/32" for 1/8" electrodes) and run stringer beads. For fill and cover passes, a weaving technique is best employed. When AC welding, it is recommended to set the machine at the higher end of the range.

E71T-GS Flux-Cored MIG Wire PREMIUM GASLESS, FLUX-CORED MILD STEEL, ALL POSITION FOR MAINTENANCE AND REPAIR WELDING OF MILD STEEL AND GALVANIZED STEELS. General Characteristics This self-shielded, flux-cored, mild steel wire is designed for single pass, semi-automatic welding applications encountered by the maintenance and repair welder. It is excellent for carbon steels, galvanized steels and zinccoated steels. The specially formulated flux contained inside the wire eliminates the need for an external shielding gas and provides the necessary slag to produce the same high quality weld as US Forge Steel. US Forge Flux-Cored MIG Wire is excellent for use with small constant current wire feeders which are lightweight. Applications Fabrication and repair of lightweight structural steel, trailers, tanks, hoppers and machinery parts. Excellent for use on fillet and lap welds on thin gauge steel where burn through is a problem with other wires and electrodes. An ideal electrode to use in drafty or windy conditions where gas-shielded wire cannot be used. Technical Data Typical Tensile Strength: up to 83,000 psi Current: DCEN (electrode-) Diameters Available: .030", .035", .045" Spool Sizes Available: 2 lb., 10lb. SPECIFICATIONS: AWS A5.20 SFA 5.20 E71T-GS RECOMMENDED WELDING PARAMETERS: Diameter Volts Amps Wire Stickout Approx. .030" 14-17 25-100 3/8" - 1/2"

.035" 13-19 50-150 3/8" - 1/2" .045" 15-18 75-200 1/2" - 3/4"

ER70S-6 SOLID MILD STEEL MIG WIRE General Characteristics The US Forge ER70S-6 is an excellent wire designed for single and multiple pass welding. It can also be used for sheet metal applications when smooth welds are needed. A shielding gas is required when welding with this wire. Applications Fabrication and repair of lightweight structural steel. Excellent choice for welding Low Carbon Steel (Mild Steel). Ideal for body panel repair, fences, yard tools, etc. Technical Data Current: DC Reverse Shielding: Gas Co2 Typical Tensile Strength: 70,000 psi Typical Yield Strength: 58,000 psi Elongation: 22% RECOMMENDED WELDING PARAMETERS: Diameter Volts Amps .023" 40 125 .030" 50 150 .035" 75 175 Procedure Clean area to be welded with wire brush, grinder, etc. Weld area to be free of paint, rust, grease, oil, etc. Base material 1/4" or thicker should be beveled prior to joining.

ER5356 ALUMINUM MIG WIRE

General Characteristics The US Forge ER5356 has a high magnesium content. This will help increase weld strength and decrease crack sensitivity when welding on base metals; 5086, 5083 or 5456. The US Forge ER5356 also provides excellent ductility when welding base metals; 5456, 6061, 6063, 7005 and 7039. Applications Excellent for repair of automotive, truck and bus parts. Also for tanks, pipes, ladders, shelves, regrigeration equipment, foundry patterns and many other aluminum structures. Repair of machining errors and buildup of missing sections of casting, extrusions, plates, etc. Technical Data US Forge ER5356 meets AWS A5.10 ER5356 Current: DC Reverse Shielding Gas: 100% Argon RECOMMENDED WELDING PARAMETERS: Diameter Volts Amps .030" 15-22 70-110 .035" 17-24 75-115 Procedure Use a stainless steel brush to clean the weld area. The stainless steel brush should be used only for aluminum. Base material 1/4" and thicker should be beveled prior to welding.

ER308L STAINLESS STEEL MIG WIRE General Characteristics US Forge ER308L is an excellent choice for welding stainless steel and provides a smooth, clean and bright surface. Applications This wire is designed for dairy, pulp, paper, refinery and

chemical equipment. Low carbon content reduces carbide precipitation. Technical Data Current: DC Reverse Shielding Gas: 75% Argon, 25% Co2 Amps: 40-130 Volts: 14-20 SPECIFICATIONS: AWS A5.9 ER308L SFA 5.9 Procedure Clean materials of foreign substances, set parameters to ranges recommended (appropriate for base metal thickness and position) by machine manufacturer. Use stringer passes to minimize overheating which can cause distortion.

Definitions of Welding Terms AC or Alternating Current: Electricity which reverses its direction based on current cycle (sine wave). For 60 cycle current, the current goes in one direction and then in the other direction 60 times in the same second, so that the current changes its direction 120 times in one second. Arc Blow: Magnetic disturbance of the arc which causes it to waver from its intended path. Arc Length: The distance from the end of the electrode to the point where the arc makes contact with the work surface. As Welded: The condition of weld metal, welded joints and weldments after welding prior to any subsequent thermal or mechanical treatment. Base Metal: The metal to be welded. Butt Joint: A joint between two members aligned approximately in the same place.

Carbon: The addition of carbon to steel increases its ability to harden and adds strength and wear resistance. Carbon Steel: Steel that owes its properties chiefly to the presence of carbon, without substantial amounts of other alloying elements; also termed ordinary steel, straight carbon steel, plain carbon steel. Chromium: Chromium raised the ultimate strength, hardness and toughness, and adds wear resistance to steel. Coated Electrode: A filler-metal electrode, used in arc welding, consisting of a metal core wire with a relatively thick covering which provides protection for the molten metal and stabilizes the arc. DC or Direct Current: Electric current which flows only in one direction. In welding an arc welding process wherein the power supply at the arc is direct current. Flat Position: The welding position used to weld from the upper side of the joint, the face of the weld is approximately horizontal. Flux: Material used to prevent, dissolve, or facilitate removal of oxides and other undesirable surface substances. Low Carbon Steel: Steel containing 20% or less carbon. Refferred to as mild steel. Manganese: Manganese helps to make the steel sound, increases the depth of hardening and makes it easier to work. Molybdenum: Molybdenum increases red hardness, wear resistance, hardness depth, and inclines the steel to oil or air hardening. Nickel: Nickel adds toughness and wear resistance to steel when used in conjunction to other alloys such as chromium.

Open-Circuit Voltage: The voltage between the output terminals of the welding machine when no current is flowing in the welding circuit. Pass (also: Weld Pass): A single progression of a welding or surfacing operation along a joint, weld deposit or substrate. The result of a pass is a weld bead, layer or spray deposit. Peening: Mechanical working of metal by means of hammer blows. Penetration: The distance the fusion zone extends below the surface of the part or parts being welded. Porosity: Gas pockets or voids in metal. Postheating: A process used immediately after welding, whereby heat is applied to the weld zone either for tempering or for providing a controlled rate of cooling, in order to avoid a hard or brittle structure. Reverse Polarity: The arrangement of arc welding leads wherein the work is the negative pole and the electrode is the positive pole in the arc circuit. Slag Inclusion: Non-metallic solid material entrapped in weld metal or between weld metal and base metal. Spatter: In arc and gas welding, the metal particles expelled during welding and which do not form a part of the weld. Straight Polarity: The arrangement of arc welding leads wherein the work is the positive pole and the electrode is the negative pole of the arc circuit. Stringer Bead: A type of weld bead made without appreciable transverse oscillation. Tack Weld: A weld (generally short) made to hold parts of a weldment in proper alignment until the final welds are made.

Tensile Strength: The value obtained by dividing the maximum load observed during tensile straining by the specimen cross sectional area before straining. Also called ultimate strength. Underbead Crack: A crack in the heat affected zone not extending to the surface of the base metal. Vanadium: Retards grain growth, increases toughness, may add red hardness and permits higher hardening or quenching temperatures. Weaving: A technique of depositing weld metal in which the electrode is oscillated. Weld Metal: That portion of a weld which had been melted during welding. Whipping: A term applied to an inward and upward movement of the electrode which is employed in vertical welding to avoid undercut. Yield Strength: The stress at which a material exhibits a specified limiting deviation from proportionality of stress to strain. An offset of 0.2% is used for many metals such as aluminum- base and magnesium-base alloys, while a 0.5% total elongation under load is frequently used for copper alloys.

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TROUBLESHOOTING PROCEDURES OXYACETYLENE WELDING 1. DISTORTION (fig. C-1) Step 1. Check to see whether shrinkage of deposited metal has pulled welded parts together. a. Properly clamp or tack weld parts to resist shrinkage. b. Separate or preform parts sufficiently to allow for shrinkage of welds. c. Peen the deposited metal while still hot. Step 2. Check for uniform heating of parts during welding. a. Support parts of structure to be welded to prevent buckling in heated sections due to weight of parts themselves. b. Preheating is desirable in some heavy structures. c. Removal of rolling or forming strains before welding is sometimes helpful. Step 3. Check for proper welding sequence. a. Study the structure and develop a definite sequence of welding. b. Distribute welding to prevent excessive local heating. 2. WELDING STRESSES Step 1. Check the joint design for excessive rigidity. a. Slight movement of parts during welding will reduce welding stresses. b. Develop a welding procedure that permits all parts to be free to move as long as possible. Step 2. Check for proper welding procedure. a. Make weld in as few passes as practical. b. Use special intermittent or alternating welding sequence and backstep or skip welding procedure. c. Properly clamp parts adjacent to the joint. Use backup fixtures to cool parts rapidly. Step 3. If no improper conditions exist, stresses could merely be those inherent in any weld, especially in heavy parts. Peen each deposit of weld metal. Stress relieve finished product at 1100 to 1250F (593 to 677C) 1 hour per 1.0 in. (25.4 cm) of thickness. 3. WARPING OF THIN PLATES (fig. C-2)

Step 1. Check for shrinkage of deposited weld metal. Distribute heat input more evenly over full length of seam. Step 2. Check for excessive local heating at the joint. Weld rapidly with a minimum heat input to prevent excessive local heating of the plates adjacent to the weld. Step 3. Check for proper preparation of the joint. a. Do not have excessive space between the parts to be welded. Prepare thin plate edges with flanged joints, making offset approximately equal to the thickness of the plates. No filler rod is necessary for this type of joint. b. Fabricate a U-shaped corrugation in the plates parallel to and approximately 1/2 in. (12.7 mm) away from the seam. This will serve as an expansion joint to take up movement during and after the welding operation. Step 4. Check for proper welding procedure. a. Use special welding sequence and backstep or skip procedure. b. Preheat material to relieve stress. Step 5. Check for proper clamping of parts. Properly clamp parts adjacent to the joint. Use backup fixtures to cool parts rapidly. 4. POOR WELD APPEARANCE (fig. C-3) Step 1. Check the welding technique, flame adjustment, and welding rod manipulation. a. Ensure the use of the proper welding technique for the welding rod used. b. Do not use excessive heat. c. Use a uniform weave and welding speed at all times. Step 2. Check the welding rod used, as the poor appearance may be due to the inherent characteristics of the particular rod. Use a welding rod designed for the type of weld being made. Step 3. Check for proper joint preparation. Prepare all joints properly. 5. CRACKED WELDS (fig. C-4) Step 1. Check the joint design for excessive rigidity.

Redesign the structure or modify the welding procedure in order to eliminate rigid joints. Step 2. Check to see if the welds are too small for the size of the parts joined. Do not use too small a weld between heavy plates. Increase the size of welds by adding more filler metal. Step 3. Check for proper welding procedure. a. Do not make welds in string beads. Deposit weld metal full size in short sections 8.0 to 10.0 in. (203.2 to 254.0 mm) long. (This is called block sequence.) b. Welding sequence should be such as to leave ends free to move as long as possible. c. Preheating parts to be welded sometimes helps to reduce high contraction stresses caused by localized high temperatures. Step 4. Check for poor welds. Make sure welds are sound and the fusion is good. Step 5. Check for proper preparation of joints. Prepare joints with a uniform and proper free space. In some cases a free space is essential. In other cases a shrink or press fit may be required. 6. UNDERCUT Step 1. Check for excessive weaving of the bead, improper tip size, and insufficient welding rod added to molten puddle. a. Modify welding procedure to balance weave of bead and rate of welding rod deposition, using proper tip size. b. Do not use too small a welding rod. Step 2. Check for proper manipulation of the welding. a. Avoid excessive and nonuniform weaving. b. A uniform weave with unvarying heat input will aid greatly in preventing undercut in butt welds. Step 3. Check for proper welding technique -- improper welding rod deposition with nonuniform heating. Do not hold welding rod too near the lower edge of the vertical plate when making a horizontal fillet weld, as undercut on the vertical plate will result. 7. INCOMPLETE PENETRATION (fig. C-5) Step 1. Check for proper preparation of joint.

a. Be sure to allow the proper free space at the bottom of the weld. b. Deposit a layer of weld metal on the back side of the joint, where accessible, to ensure complete fusion at the root of the joint. Step 2. Check the size of the welding rod used. a. Select proper sized welding rod to obtain a balance in the heat requirements for melting welding rod, breaking down side walls, and maintaining the puddle of molten metal at the desired size. b. Use small diameter welding rods in a narrow welding groove. Step 3. Check to see if welding tip is too small, resulting in insufficient heat input. Use sufficient heat input to obtain proper penetration for the plate thickness being welded. Step 4. Check for an excessive welding speed. Welding speed should be slow enough to allow welding heat to penetrate to the bottom of the joint. 8. POROUS WELDS (fig. C-6) Step 1. Check the inherent properties of the particular type of welding rod. Use welding rod of proper chemical analysis. Step 2. Check the welding procedure and flame adjustment. a. Avoid overheating molten puddle of weld metal. b. Use the proper flame adjustment and flux, if necessary, to ensure sound welds. Step 3. Check to see if puddling time is sufficient to allow entrapped gas, oxides, and slag inclusions to escape to the surface. a. Use the multilayer welding technique to avoid carrying too large a molten puddle of weld metal. b. Puddling keeps the weld metal longer and often ensures sounder welds. Step 4. Check for poor base metal. Modify the normal welding procedure to weld poor base metals of a given type. 9. BRITTLE WELDS Step 1. Check for unsatisfactory welding rod, producing air-hardening weld metal. Avoid welding rods producing air-hardening weld metal where ductility is desired. High tensile strength, low alloy steel rods are air-hardened and require proper base metal preheating, postheating, or both to avoid cracking due to brittleness.

Step 2. Check for excessive heat input from oversized welding tip, causing coarse-grained and burnt metal. Do not use excessive heat input, as this may cause coarse grain structure and oxide inclusions in weld metal deposits. Step 3. Check for high carbon or alloy base metal which has not been taken into consideration. Welds may absorb alloy elements from the patent metal and become hard. Do not weld a steel unless the composition and characteristics are known. Step 4. Check for proper flame adjustment and welding procedure. a. Adjust the flare so that the molten metal does not boil, foam, or spark. b. A single pass weld maybe more brittle than multilayer weld, because it has not been refined by successive layers of weld metal. 10. POOR FUSION (fig. C-7) Step 1. Check the welding rod size. When welding in narrow grooves, use a welding rod small enough to reach the bottom. Step 2. Check the tip size and heat input. Use sufficient heat to melt welding rod and to break down sidewalls of plate edges. Step 3. Check the welding technique. Be sure the weave is wide enough to melt the sides of the joint thoroughly. Step 4. Check for proper preparation of the joint. The deposited metal should completely fuse with the side walls of the plate metal to form a consolidated joint of base and weld metal. 11. CORROSION Step 1. Check the type of welding rod used. Select welding rods with the proper corrosion resistance properties which are not changed by the welding process. Step 2. Check whether the weld deposit is proper for the corrosive fluid or atmosphere. a. Use the proper flux on both parent metal and welding rod to produce welds with the desired corrosion resistance. b. Do not expect more from the weld than from the parent metal. On stainless steels, use welding rods that are equal to or better than the base metal in corrosion resistance.

c. For best corrosion resistance, use a filler rod whose composition is the same as the base metal. Step 3. Check the metallurgical effect of welding. When welding 18-8 austenitic stainless steel, be sure the analysis of the steel and the welding procedure are correct, so that the welding process does not cause carbide precipitation. This condition can be corrected by annealing at 1900 to 2100F (1038 to 1149C). Step 4. Check for proper cleaning of weld. Certain materials such as aluminum require special procedures for thorough cleaning of all slag to prevent corrosion. 12. BRITTLE JOINTS Step 1. Check base metal for air hardening characteristics. In welding on medium carbon steel or certain alloy steels, the fusion zone may be hard as the result of rapid cooling. Preheating at 300 to 500F (149 to 260C) should be resorted to before welding. Step 2. Check welding procedure. Multilayer welds will tend to anneal hard zones. Stress relieving at 1000 to 1250F (538 to 677C) after welding generally reduce hard areas formed during welding. Step 3. Check type of welding rod used. The use of austenitic welding rods will often work on special steels, but the fusion zone will generally contain an alloy which is hard. ARC WELDING 13. DISTORTION (fig. C-1) Step 1. Check for shrinkage of deposited metal. a. Properly tack weld or clamp parts to resist shrinkage. b. Separate or preform parts so as to allow for shrinkage of welds. c. Peen the deposited metal while still hot. Step 2. Check for uniform heating of parts. a. Preheating is desirable in some heavy structures. b. Removal of rolling or forming strains by stress relieving before welding is sometimes helpful. Step 3. Check the welding sequence. a. Study structure and develop a definite sequence of welding. b. Distribute welding to prevent excessive local heating.

14. WELDING STRESSES Step 1. Check for excessive rigidity of joints. a. Slight movement of parts during welding will reduce welding stresses. b. Develop a welding procedure that permits all parts to be free to move as long as possible. Step 2. Check the welding procedure. a. Make weld in as few passes as practical. b. Use special intermittent or alternating welding sequence and backstep or skip procedures. c. Properly clamp parts adjacent to the joint. Use backup fixtures to cool parts rapidly. Step 3. If no improper conditions exist, stresses could merely be those inherent in any weld, especially in heavy parts. a. Peen each deposit of weld metal. b. Stress relieve finished product at 1100 to 1250F (593 to 677C) 1 hour per 1.0 in. (25.4 cm) of thickness. 15. WARPING OF THIN PLATES (fig. C-2) Step 1. Check for shrinkage of deposited weld metal. Select electrode with high welding speed and moderate penetrating properties. Step 2. Check for excessive local heating at the joint. Weld rapidly to prevent excessive local heating of the plates adjacent to the weld. Step 3. Check for proper preparation of joint. a. Do not have excessive root opening in the joint between the parts to be welded. b. Hammer joint edges thinner than the rest of the plates before welding. This elongates the edges and the weld shrinkage causes them to pull back to the original shape. Step 4. Check the welding procedure. a. Use special intermittent or alternating welding sequence and backstep or skip procedure. b. Preheat material to achieve stress. Step 5. Check the clamping of parts. Properly clamp parts adjacent to the joint. Use backup fixtures to cool parts rapidly. 16. POOR WELD APPEARANCE (fig. C-3) Step 1. Check welding technique for proper current and electrode manipulation.

a. Ensure the use of the proper welding technique for the electrode used. b. Do not use excessive welding current. c. Use a uniform weave or rate of travel at all times. Step 2. Check characteristics of type of electrode used. Use an electrode designed for the type of weld and base metal and the position in which the weld is to be made. Step 3. Check welding position for which electrode is designed. Do not make fillet welds with downhand (flat position) electrodes unless the parts are positioned properly. Step 4. Check for proper joint preparation. Prepare all joints properly. 17. CRACKED WELDS (fig. C-4) Step 1. Check for excessive rigidity of joint. Redesign the structure and modify the welding procedure in order to eliminate rigid joints. Step 2. Check to see if the welds are too small for the size of the parts joined. Do not use too small a weld between heavy plates. Increase the size of welds by adding more filler metal. Step 3. Check the welding procedure. a. Do not make welds in string beads. Deposit weld metal full size in short sections 8.0 to 10.0 in. (203.2 to 254.0 mm) long. (This is called block sequence.) b. Welding sequence should be such as to leave ends free to move as long as possible. c. Preheating parts to be welded sometimes helps to reduce high contraction stresses caused by localized high temperature. d. Fill all craters at the end of the weld pass by moving the electrode back over the finished weld for a short distance equal to the length of the crater. Step 4. Check for poor welds. Make sure welds are sound and the fusion is good. Be sure arc length and polarity are correct. Step 5. Check for proper preparation of joints. Prepare joints with a uniform and proper root opening. In some cases, a root opening is essential. In other cases, a shrink or press fit may be required.

18. UNDERCUT Step 1. Check the welding current setting. Use a moderate welding sent and do not try to weld at too high a speed. Step 2. Check for proper manipulation of the electrode. a. Do not use too large an electrode. If the puddle of molten metal becomes too large, undercut may result. b. Excessive width of weave will cause undercut and should not be used. A uniform weave, not over three times the electrode diameter, will aid greatly in preventing undercut in butt welds. c. If an electrode is held to near the vertical plate in making a horizontal fillet weld, undercut on the vertical plate will result. 19. POOR PENETRATION (fig. C-5) Step 1. Check to see if the electrode is designed for the welding position being used. a. Electrodes should be used for welding in the position for which they were designed. b. Be sure to allow the proper root openings at the bottom of a weld. c. Use a backup bar if possible. d. Chip or cut out the back of the joint and deposit a bead of weld metal at this point. Step 2. Check size of electrode used. a. Do not expect excessive penetration from an electrode. b. Use small diameter electrodes in a narrow welding groove. Step 3. Check the welding current setting. Use sufficient welding current to obtain proper penetration. Do not weld too rapidly. Step 4. Check the welding speed. Control the welding speed to penetrate to the bottom of the welded joint. 20. POROUS WELDS (fig. C-6) Step 1. Check the properties of the electrode used. Some electrodes inherently produce sounder welds than others. Be sure that proper electrodes are used. Step 2. Check welding procedure and current setting. A weld made of a series of string beads may contain small pinholes. Weaving will often eliminate this trouble.

Step 3. Check puddling time to see whether it is sufficient to allow entrapped gas to escape. Puddling keeps the weld metal molten longer and often insures sounder welds. Step 4. Check for dirty base metal. In some cases, the base metal may be at fault. Check this for segregations and impurities. 21. BRITTLE WELDS Step 1. Check the type of electrode used. Bare electrodes produce brittle welds. Shielded arc electrodes must be used if ductile welds are required. Step 2. Check the welding current setting. Do not use excessive welding current, as this may cause coarse-grained structure and oxidized deposits. Step 3. Check for high carbon or alloy base metal which has not been taken into consideration. a. A single pass weld may be more brittle than a multilayer weld because its microstructure has not been refined by successive layers of weld metal. b. Welds may absorb alloy elements from the parent metal and become hard. c. Do not weld a metal unless the composition and characteristics are known. 22. POOR FUSION (fig. C-7) Step 1. Check diameter of electrode. When welding in narrow groove joints use an electrode small enough to properly reach the bottom of the joint. Step 2. Check the welding current setting. a. Use sufficient welding current to deposit the metal and penetrate into the plates. b. Heavier plates require higher current for a given electrode than light plates. Step 3. Check the welding technique. Be sure the weave is wide enough to melt the sidewalls of the joint thoroughly. Step 4. Check the preparation of the joint. The deposited metal should fuse with the base metal and not curl away from it or merely adhere to it. 23. CORROSION Step 1. Check the type of electrode used.

a. Bare electrodes produce welds that are less resistant to corrosion than the parent metal. b. Shield arc electrodes produce welds that are more resistant to corrosion than the parent metal. c. For the best corrosion resistance, use a filler rod whose composition is similar to that of the base metal. Step 2. Check to see if the weld metal deposited is proper for the corrosive fluid or atmosphere to be encountered. Do not expect more from the weld than you do from the parent metal. On stainless steels, use electrodes that are equal to or better than the parent metal in corrosion resistance. Step 3. Check on the metallurgical effect of the welding. When welding 18-8 austenitic stainless steel, be sure the analysis of the steel and welding procedure is correct, so that the welding does not cause carbide precipitations. Carbide precipitation is the rising of carbon to the surface of the weld zone. This condition can be corrected by annealing at 1900 to 2100F (1038 to 1149C) after welding. By doing this corrosion in the form of iron oxide, or rust, can be eliminated. Step 4. Check for proper cleaning of the weld. Certain materials, such as aluminum, require careful cleaning of all slag after welding to prevent corrosion in service. 24. BRITTLE JOINTS Step 1. Check for air hardening of the base metal. In medium carbon steel or certain alloy steals, the heat affected zone may be hard as a result of rapid cooling. Preheating at 300 to 500F (149 to 260C) should be resorted to before welding. Step 2. Check the welding procedure. a. Multilayer welds will tend to anneal hard heat affected zones. b. Stress relieving at 1100 to 1250F (593 to 677C) after welding will generally reduce hard areas formed during welding. Step 3. Check the type of electrode used. The use of austenitic electrodes will often be successful on special steels, but the heat-affected zone will generally contain an alloy which is hard. 25. MAGNETIC BLOW Step 1. Check for deflection of the arc from its normal path, particularly at the ends of joints and in corners. a. Make sure the ground is properly located on the work. Placing the ground in the direction of the arc deflection is often helpful.

b. Separating the ground into two or more parts is helpful. c. Weld toward the direction in which the arc blows. d. Hold a short arc. e. Changing the angle of the electrode relative to the work may help to stabilize the arc. f. Magnetic blow is held to a minimum in alternating current welding. 26. SPATTER Step 1. Check the properties of the electrode used. Select the proper type of electrode. Step 2. Check to see if the welding current is excessive for the type and diameter of electrode used. Use a short arc but do not use excessive welding current Step 3. Check for spalls. a. Paint parts adjacent to welds with whitewash or other protective coating. This prevents spalls from welding to parts, and they can be easily removed. b. Coated electrodes produce larger spalls than bare electrodes.